Modeling and Prediction

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    Proceedings of the Fortieth Turbomachinery Symposium

    September 12-15, 2011, Houston, Texas

    MODELING AND PREDICTION OF SIDESTREAM INLET PRESSURE FOR MULTISTAGE CENTRIFUGAL

    COMPRESSORS

    Jay Koch

    Principal Engineer

    Dresser-Rand

    Olean, NY, USA

    Jim Sorokes

    Principal Engineer

    Dresser-Rand

    Olean, NY, USA

    Moulay Belhassan

    Principal Engineer

    Dresser-Rand

    Olean, NY, USA

    .

    ABSTRACT

    It is common for some compressors in certain applications

    to have one or more incoming sidestreams that introduce flow

    other than at the main inlet to mix with the core flow. In most

    cases, the pressure levels at these sidestreams must be

    accurately predicted to meet contractual performance

    guarantees. The focus of this paper is the prediction of

    sidestream flange pressure when the return channel outlet

    conditions are provided. A model to predict the impact of local

    curvature in the mixing section is presented and compared with

    both Computational Fluid Dynamics work and measured test

    data.

    INTRODUCTION

    Despite recent advances in analytical tools, developers and

    users of state-of-the-art centrifugal compressor equipment

    continue to rely heavily on testing to ultimately confirm the

    performance of new components or stages. This is especially

    true in heavy hydrocarbon applications such as compressors

    used in liquefied natural gas (LNG), ethylene, or gas-to-liquid

    facilities. Heavy hydrocarbon gases have very low gas sonic

    velocities that produce high Mach numbers in the aerodynamic

    flowpath. By their nature, such high Mach number, high flow

    coefficient stages have very narrow flow maps characterized by

    limited choke and surge margin. In addition, many of theseapplications require the machines with sidestreams (or

    sideloads) to accommodate the flows entering and/or exiting

    the compressor as determined by the particular process for

    which they are intended. The sidestreams and associated

    mixing further complicate the performance prediction process

    because the pressure, temperature and flow conditions at each

    one of these sidestreams as well as at the exit of the machine

    must be met within stringent tolerances to optimize the amount

    of end product delivered by the process. Therefore, it is

    imperative that the compressor OEM and end user have a firm

    grasp of the performance characteristics of any impellers

    diffusers, return channels, and/or other flow path components

    used in such equipment.

    The high cost associated with delays in the projec

    schedule increase the attractiveness of design and testing

    methods that ensure these machines meet the contractua

    operating requirements the first time; without the need for

    repeated modifications and test iterations to correc

    performance shortfalls. Given the size, construction style, and

    in-house test piping arrangements for many large centrifugals

    one modification / re-test iteration could take several weeks

    Repeated iterations on the OEMs test facility could delay the

    start-up of a new plant by months, leading to lost production /

    revenue for the end user as well as lost revenue and reputationfor the compressor OEM. Consequently, OEMs spend

    continually work to enhance their performance prediction

    methods. This paper details work done toward that end.

    This paper is the latest in a continuing series of publications

    describing work completed in association with a novel test

    vehicle that was designed to replicate the performance of a full-

    scale, large frame-size, multi-stage centrifugal compressor for

    high flow coefficient, high Mach number stages. The test

    vehicle, described by Sorokes et al (2009), is equipped with a

    vast array of internal instrumentation that make it possible to

    evaluate the aero/thermodynamic and mechanical behavior of a

    compressor. Sufficient instrumentation is installed to allow

    assessment of the entire compressor as well as individualcomponents or combinations of components. Of particular

    interest to this study, the test rig included instrumentation at

    critical locations within the sidestream components to permit an

    assessment of the losses through each sidestream element.

    BACKGROUND

    As part of the compressor selection and design process, the

    OEM must be able to predict the performance of the overall

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    unit from inlet to discharge flange. For a simple, so-called

    straight through compressor, this means predicting the

    performance for each stage (inlet guide / impeller / diffuser /

    return channel or volute) in series from the inlet to the

    discharge of the machine. However, for units with one or more

    incoming sidestreams, there is the additional task of accounting

    for the impact of the sidestream and thereby predicting the

    conditions at the intermediate flange; i.e., static and total

    pressure.

    Typically, OEMs supply compressor performance curves

    that reflect flange-to-flange performance because that is what

    the process engineer needs to ensure proper operation of their

    system. Such data is easier to monitor when a compressor is

    installed in the field. However, flange-to-flange data, if not

    interpreted properly can lead to misleading conclusions as to

    the relative performance of individual sections of a

    compression system. For example, if the sidestream losses

    from the flange to mixing section are attributed to the upstream

    section, it will cause the upstream section to appear low in

    performance while the downstream section will show

    erroneously high performance levels; i.e., efficiency

    significantly higher than 90%). The need for a more refined

    method for allocating sidestream losses as well as the need to

    eliminate other uncertainties regarding the sidestream lossmechanisms has led to additional research on sidestream

    performance modeling.

    Compressor OEMs have completed significant work in

    recent years to improve their understanding of the flow in

    sidestreams and sidestream mixing section as well as the impact

    of the mixed stream on the downstream impeller. In most

    cases, the portion of the sidestream from the flange connection

    to the mixing section (i.e., the location where the incoming

    sidestream flow mixes with the core flow) is very similar to a

    radial compressor inlet. There has been significant work

    reported in the literature on radial inlets. For example, Flathers

    et al (1994) compared several geometric variations using

    Computational Fluid Dynamics (CFD) and measured testresults. Koch et al (1995), Kim and Koch (2004), Michelass

    and Giachi (1997) subsequently reported similar work on

    different geometric variations. These studies all led to

    increased understanding of the flow structure and improved

    prediction methods for inlet losses and the details of the flow

    field exiting these components. Proper use of the CFD tools

    also led to more efficient / effective inlet configurations that

    provided a more circumferentially uniform flow to the

    downstream impeller. The studies also aided in the one-

    dimensional prediction of pressure losses.

    Additional studies, which included the upstream return

    channel and the complete sidestream geometry, have been

    completed to accurately model the flow where the core flow

    and sidestream flow merge. While this location is typically

    called the mixing section as noted above, the flows do not

    completely mix before entering the impeller. The works of

    Sorokes et al (2000 and 2006) and the prior referenced work on

    radial inlets have led to a greater comprehension of the

    complex flows at the sidestream mixing location. However,

    these works did not address the flow physics that determine the

    static pressure in the mixing section, which, in turn, sets the

    flange pressure level. The study by Hardin (2002) describes a

    one-dimensional method that determines how the flow at the

    mixing location and, therefore, the local static pressure is

    impacted by the local flow curvature.

    This paper presents predictions for two geometric

    configurations that violate the assumptions made in previous

    studies, resulting in a need to modify the relevant equations

    Additionally, the prior work did not present the methods used to

    predict the total pressure downstream of the mixing section

    This paper will present various methods to predict the

    downstream total pressure and compare the analytical results to

    measured test data on the two geometries.

    INVESTIGATIVE STUDY

    As part of a recent OEM development program, a study on

    several sidestream configurations was conducted. The projec

    required compact sidestream mixing sections; i.e., mixing

    sections that take less axial length; in a compressor with high

    flow coefficient ( > 0.10) and high machine Mach number

    (i.e., U2/A0 > 1.1). The sidestreams were of different sizes a

    the incoming flows represented different percentages of the

    flow from the upstream section. The gas density in the

    sidestreams also varied due to the increasing pressure in the

    machine. Finally, the machine was tested using a high mole

    weight refrigerant to replicate the high gas densities and Machnumbers. Representative geometry for a typical configuration

    is shown in Figures 1a and 1b.

    Figure1a. Geometry for configuration 1

    Figure1b. Geometry for configuration 1 section A- A

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    During the detailed design process, each proposed stage

    geometry was modeled using a commercially available CFD

    code, ANSYS CFX-10. As part of this study, the sidestream

    inlet geometry was optimized within the available axial space

    provided. The CFD domain for each sidestream included the

    upstream diffuser, return channel, sidestream nozzle, sidestream

    plenum, mixing section, and downstream impeller. The full

    360-degree model included all passages to evaluate any

    circumferential flow non-uniformity at the exit of the

    sidestream. The upstream impeller was not included to reduce

    the size of the computational domain, thereby reducing solution

    time. This simplification also allowed the return channel exit

    conditions to be varied for different flow conditions; i.e., to

    replicate the flow conditions from maximum (choke) to

    minimum stable flow (stall / surge). Because the objective of

    the study was to predict the sidestream flange pressure, when

    provided return channel exit conditions, it was felt this

    simplification would have a minimal impact on the flow

    physics of interest.

    The geometry was modeled using a combination of

    hexahedral and tetrahedral elements. All axisymmetric

    components, such as the diffuser and return channel, were

    modeled using hexahedral elements and the non-uniform

    components, such as the sidestream nozzle and plenum section,were modeled using tetrahedral elements because such

    components are more easily modeled using tets. The grids

    were refined for each component and grid element type as it is

    recognized that higher grid densities are required for tetrahedral

    as opposed to hexahedral elements. Each component had a grid

    size of approximately 2 million elements and the total grid size

    was approximately 6 million elements. For the sidestream

    inlet, the grid density used is similar to those reported by the

    current authors in Kim and Koch (2004).

    The boundary conditions of the model were based on the

    one-dimensional predictions used to select and size the

    hardware. The prescribed flow angle, total pressure and totaltemperature were specified at the diffuser entrance. Total

    temperature and mass flow were specified at the sidestream

    entrance and total mass flow was specified at the exit of the

    computational domain. The inlet pressure at the sidestream

    entrance was the objective function of the analysis.

    A second order discretization scheme was used for the

    simulation and standard k- model was adopted as a turbulence

    model combined with a scalable wall function approach that

    eliminates the necessity of discretely resolving the large

    gradients in the thin, near-wall region. The convergence

    criterion was set to the maximum residual of 10-4

    for u, v, w,

    and p.

    For the two sidestream configurations addressed in thispaper, the internal elements, return channel vanes, sidestream

    vanes and inlet guide vanes, were fixed during the optimization.

    Only the meridional passage width was varied.

    In the first configuration (designated Configuration 1), the

    core flow (i.e., flow exiting the upstream return channel) and

    incoming sidestreams flows were nearly equal. This geometry

    is shown in Figures 1a and 1b. The second configuration

    (Configuration 2) was for a higher pressure and hence higher

    density stage and had a core flow that was much greater than

    the sidestream flow. The details of this mixing section

    geometry can be seen in Figure 2.

    Figure 2. Mixing section geometry for configuration 2

    The design values of area ratio (return channel exit area to

    sidestream exit area), density, and return channel exit Mach

    number are provided in Table 1.

    Table 1. Sidestream Design Parameters

    The results of the CFD study are shown in Figures 3-6

    The Mach number distribution in the sidestream nozzle for

    configuration 1 is shown in Figure 3. This configuration show

    the vane rows in the sidestream are oriented with the flow to

    provide a circumferentially uniform velocity profile at the exit

    of the sidestream. A meridional view providing the Mach

    number distribution in the mixing section is shown in Figure 4This plot shows a variation in the Mach number across the

    sidestream exit. The variation in Mach number is also eviden

    at the exit of the return channel as the flow turns to enter the

    downstream impeller.

    Density Area Ratio Mach

    lb/ft3

    Main/Sidestream Number

    1 0.30 0.76 0.34

    2 1.00 4.96 0.26

    Configuration

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    Figure 3. Mach number in sidestream configuration 1

    Figure 4. Mach number at sidestream mixing location -

    configuration 1

    Figure 5. Static pressure at the sidestream mixing location -

    configuration 1

    Figure 6. Static pressure at the sidestream mixing location

    configuration 2

    Contours of the static pressure at the same location are

    shown in Figure 5. It is evident from this figure that the static

    pressure varies from the shroud wall at the exit of the

    sidestream to the hub wall downstream of the return channel

    Because of the lower static pressure at the sidestream exit, the

    total pressure at this location is lower even though the velocity

    upstream of the curvature is roughly matched for both streams.

    This phenomenon of reduced pressure at the sidestream

    exit was predicted by Hardin (2002). Based on the

    relationships shown in that work, this variation in pressure can

    be expected to increase with dynamic pressure, 22V , and

    with larger variations in curvature between the two streams.

    A plot of static pressure for configuration 2 is shown in

    Figure 6. This configuration shows similar trends to

    configuration 1 with significant variation in the static pressure

    from the exit of the return channel to the exit of the sidestream.

    In reviewing these configurations it is evident that the

    specific formulation developed in the prior work does not apply

    to this geometry. A major assumption put forth in the prior

    work was that there was no variation in the static pressure at the

    outlet of the return channel passage. Thus the effect o

    curvature was only applied across the sidestream exit. For this

    geometry, the formulation must be modified to account for the

    variation across both the return channel exit and the sidestream

    exit. While simple in nature, this can have a significant impac

    on the predicted static pressure at the sidestream exit.

    Before developing a method to account for the changes in

    curvature, an optimization study was conducted on the mixing

    section of configuration 2. To reduce the execution time and

    allow for more design iterations, a sub-model was created that

    included a portion of the return channel vane exit and a portion

    of the exit of the plenum section of the sidestream just upstream

    of the mixing section. The upstream diffuser and return

    channel as well as the sidestream plenum were removed from

    the sub-model. This also allowed the geometry to be modeled

    as a pie slice section as opposed to a full 360 model

    Comparison of sub-model and full model solutions revealedthat the simplified model captured the important flow features

    in the mixing section. Therefore, the simplified model was

    used for the optimization study for the mixing section.

    PREDICTION METHODOLOGY

    To accurately predict the sidestream exit conditions, proper

    boundary conditions for the problem must be established. The

    exit conditions at the return channel are generally known from

    one-dimensional predictions or from test measurements

    Therefore, for this discussion it was assumed the discharge tota

    pressure was known at the exit of the return channel preceding

    the mixing section. Additionally, it is assumed the area, flowrate, temperature and gas properties were known at the return

    channel exit and at the sidestream exit.

    Given the referenced information, the return channel exi

    mean velocity and static pressure can be calculated. Based on

    basic flow principles, it was assumed that the static pressure

    was equal between both flow streams at the mixing location

    The only location where this is true is at the shroud wall at the

    exit of the return channel and the hub wall at the exit of the

    sidestream. This assumption is supported by the previou

    computational study completed by the OEM and by other

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    researchers such as Hardin (2002). Unfortunately, the pressure

    at this location is not as desired because of the local curvatures

    in the mixing section. The desired result can be obtained via a

    series of equations that allow the average static pressure at the

    exit of the sidestream to be calculated from the average static

    pressure at the exit of the return channel.

    According to basic aerodynamic principles, the

    relationship of pressure versus radius of curvature can be

    expressed by Equation (1).

    R

    V

    dR

    dP2

    = (1)

    For the geometry shown in Figure 7, the average static

    pressure at the exit of the return channel can be related to the

    average pressure at the exit of the sidestream by the variation in

    curvature using Equation 1. The average static pressure at the

    sidestream exit is defined by Equation (2).

    ( )

    t

    sst

    tss

    c

    cc

    ss

    R

    RRVPP

    Re

    Re

    Re

    2

    +=

    (2)

    Where:

    sssP = Static pressure at sidestream exit

    tsP

    Re

    = Static pressure at return channel exit

    ssCR = Radius sidestream of curvature (see fig. 7)

    tCR

    Re

    = Radius of return channel curvature (see fig. 7)

    = Gas density

    V = Velocity at the sidestream exit

    Figure 7. Geometry for pressure prediction

    Once the static pressure at the sidestream exit is

    determined, the velocity and total pressure can be calculated.The flange total pressure can be calculated based on the

    predicted losses in the nozzle plenum region, once the

    sidestream exit total pressure is known (Equations (3) and (4)).

    The losses in this region of the sidestream have been shown to

    be consistent and predictable by 1-D models. The 1-D model

    for a given geometry can be based on CFD prediction or based

    on test measurements.

    2

    2V

    PPssss sT

    += (3)

    ss

    FLG

    TTLC

    VPP

    ssFLG 2

    2

    += (4)

    Where:

    sssP = Static pressure at sidestream exit

    ssTP = Total pressure at sidestream exit

    FLGTP = Total pressure at flange

    = Gas density

    V = Velocity at sidestream exit

    VFLG = Velocity at flange

    LCss = Loss coefficient

    The appropriate method for the prediction of the tota

    pressure downstream of the mixing section at the inlet of the

    impeller has not been questioned in the literature. The

    appendix of the test standard from ASME (1997), defines a

    momentum balance method, but this method is approximateAttempts to use this method have not been very successful for

    these authors or others in the open literature. The impact of the

    gradient in total pressure on the downstream impeller

    performance varies greatly. Some CFD studies indicate a

    significant impact on performance while other studies show a

    minor impact. For 1-D performance prediction purposes a

    single representative value of the impeller inlet pressure is

    desired. This representative pressure should provide a

    consistent reference between predicted performance and

    measured test results. It is also desired that the selected value

    provides a consistent reference for comparison between

    performance prediction and measured test results.

    When CFD results are evaluated, a mass-averaged totapressure at a selected plane is the common method for

    evaluation. Evaluations of test results often use an arithmetic

    average or area average based on total pressure measured by a

    single pressure probe or multi-hole pressure rake. The prio

    work by Hardin (2002) suggests mass-averaging the tota

    pressure at the exit of each stream. To determine which method

    provides a more consistent result, a set of evaluation criteria

    was developed for use on future development tests. The tes

    results will be evaluated using the three methods listed above to

    determine which method provides a more consistent result and

    therefore used for future comparisons between test results and

    analytical predictions.

    TEST DATA AND DISCUSSION

    After completion of the design study, the OEM constructed

    a full-scale development test rig; again, see Sorokes et al

    (2009). As noted, the flow path of the test rig was heavily

    instrumented to allow the measurement of the aero-

    thermodynamic performance of the components of each stage

    including the sidestream elements. The interna

    instrumentation included total pressure probes, dynamic

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    pressure probes, total temperature probes, and five-hole probes,

    which measure both pressure and flow direction. A schematic

    of the internal instrumentation layout used for each compressor

    stage is given in Figure 8.

    Figure 8. Test rig internal instrumentation layout

    For each sidestream, the total pressure and temperature

    were measured at the exit of the return channel and at the

    sidestream exit. Additionally, the total pressure and

    temperature distributions were measured near the exit of the

    mixing section; i.e. just upstream of the impeller; via pressure

    and temperature rakes. Therefore, it was possible to assess the

    hub-to-shroud variation (or stratification) in pressure and

    temperature due to the core / sidestream flow mixing.

    In addition to the internal instrumentation, the total

    pressure, total temperature and mass flow were measured at the

    flange locations using standard combination pressure /

    temperature probes.All performance testing was conducted using R-134A

    refrigerant to achieve aerodynamic similitude at the design

    conditions. The test measurements for each sidestream were

    taken in accordance with the ASME PTC-10 test code from

    ASME (1997).

    To evaluate the revised prediction scheme, the predicted

    sidestream exit total pressure was calculated at the test

    conditions and compared with the measured total pressure on

    test. The prediction was based purely on the known geometry

    and test conditions.

    For each sidestream configuration, data is presented for

    different flow rates at a fixed impeller tip Mach number of

    1.10. The flow ratio between the sidestream and the core flow

    is maintained for all operating points using the OEM stringent

    guidelines; i.e., more restrictive than the standard ASME Power

    Test Code (see Kolata and Colby (1990)). The temperatures for

    core flow and incoming sidestream streams were kept equal to

    avoid heat transfer that would add uncertainty to the efficiency

    calculation.

    The results of the prediction for configuration 1 are shown

    in Figure 9.

    0.20 0.21 0.22 0.23 0.24 0.25 0.26 0.27 0.28 0.29 0.30

    Return Channel Exit Mach Number

    -10

    -9

    -8

    -7

    -6

    -5

    -4

    -3

    -2

    -1

    0

    1

    2

    3

    4

    5

    %ErrorinSidestreamExitTo

    talPressure(Predicted/Measured)

    Prediction with Curvature Correction

    Prediction without Curvature Correction

    Figure 9. Error between test and measurement with and withou

    curvature correction configuration 1

    The percent error in the sidestream exit predicted tota

    pressure versus Mach number at the outlet of the return channe

    is shown. For configuration 1 the prediction model is within

    1.5% of the test results. As a means of determining the

    suitability of this calculation, the percent error in sidestream

    total pressure was also calculated without the curvature

    correction. This comparison showed the sidestream exit tota

    pressure was always over-predicted without the curvature

    correction. For this application, failure to account for the

    curvature effects resulted in an error of up to 5.8%. Simila

    results for configuration 2 are shown in Figure 10.

    0.18 0.19 0.20 0.21 0.22 0.23 0.24 0.25 0.26 0.27 0.28

    Return Channel Exit Mach Number

    -10

    -9

    -8

    -7

    -6

    -5

    -4

    -3

    -2

    -1

    0

    1

    2

    3

    4

    5

    %ErrorinSidestreamExitTotalPressure(Predicted/Measured)

    Prediction with Curvature CorrectionPrediction without Curvature Correction

    Figure 10. Error between test and measurement with and

    without curvature correction configuration 2

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    For configuration 2, the prediction model accounting for

    curvature is also within 1.5% of the test results. The error

    without the curvature correction is even greater than on

    configuration 1, with a maximum difference of more than 6.1%.

    Because there was considerable interest in the performance

    of the sidestream and downstream impeller with off-design

    flow functions, a set of conditions was defined to investigate

    such operating conditions. These additional data provided

    insight into prediction of the impeller inlet total pressure

    downstream of a sidestream for off-design conditions.

    During these tests the unit was intentionally tested at core

    flow to sidestream flow ratios that were at the limits of the

    ASME test standard (i.e., 10%), and thus considerably

    different than the design values. Based on the curvature

    prediction model, the flow function variation causes the

    sidestream exit pressure (and thus flange pressure) to vary from

    the design conditions. This would be true even if the

    downstream impeller inlet conditions remain unchanged.

    The change in flange pressure due to the different flow

    ratios leads to variations in the calculated section performance

    even though the impeller / diffuser / return channel

    performance remains essentially unchanged. Recall that it was

    possible to determine the performance from impeller exit to

    return channel exit because of the additional instrumentationavailable in the test vehicle. The internal performance (based

    on impeller inlet to return channel exit) and the flange to flange

    performance are shown in Figure 11 for the same operating

    conditions. There are small changes in the internal

    performance for the various sidestream flow ratios, most likely

    due to the impact on varying impeller inlet velocity profile due

    to mixing effects at the off-design flow ratios. However,

    there are more noticeable differences in the flange to flange

    calculation, particularly toward the high capacity end of the

    map.

    0.65 0.70 0.75 0.80 0.85 0.90 0.95 1.00 1.05 1.10 1.15

    Normalized Inlet Flow Coefficient

    0.40

    0.50

    0.60

    0.70

    0.80

    0.90

    1.00

    1.10

    1.20

    1.30

    1.40

    NormalizedHeadCoefficient

    Flange-to-Flange -- Design Flow Ratio

    Flange-to-Flange -- SS Flow > Design Flow Ratio

    Internal -- Design Flow Ratio

    Internal -- SS Flow > Design Flow Ratio

    Figure 11. Flange to Flange and Internal Head Coefficient for

    various sidestream flow ratios

    As part of the prediction method discussion, data from

    these tests were also used to evaluate which method of

    determining the downstream impeller inlet condition provides

    the best correlation with the test results. To complete thi

    comparison, the impeller inlet condition was calculated three

    ways. The first method was based on a mass-average of the

    total pressures at the outlet of the return channel and the

    sidestream exit. The second method used an arithmetic average

    of the total pressure rake downstream of the mixing section

    The third method was based on an area average of the

    downstream rake pressures.

    All three methods were compared using polytropic head

    coefficient, p, versus inlet flow coefficient, , (see Figure 12).

    0.8 0.85 0.9 0.95 1 1.05 1.1 1.15

    Normalized Inlet Flow Coefficient

    0.40

    0.50

    0.60

    0.70

    0.80

    0.90

    1.00

    1.10

    1.20

    1.30

    1.40

    NormalizedHeadCoefficient

    Mass Avg - Design

    Area Avg - Design

    Arithmetic Avg - Design

    Figure 12. Internal head coefficient for various total pressure

    averaging methods at the mixing section

    The data was normalized using the design point head and

    flow coefficient and trends were reviewed for both design flow

    and off-design flow conditions (i.e., from overload to

    stall/surge). For each case, the basic impeller inlet similarity

    condition remained the same. That is, the compressor was runat the same tip Mach number, and Reynolds number. However

    the sidestream flow function was allowed to vary within the

    limits of the ASME test code. As can be seen in the curves, the

    different averaging methods did result in a change in the

    perceived performance. This is not overly surprising because

    the different averaging methods will result in a different inle

    pressure to the downstream impeller and because the head

    coefficient is directly dependent on the inlet pressure, the

    resulting variation in head coefficient is to be expected.

    Specifically, the change in inlet pressure due to the various

    averaging techniques caused a shift in the inlet capacity and

    also caused a change in the head coefficient as well as a change

    in rise-to-surge for the area average method. The area-averagedmethod predicts a larger capacity and pressure coefficient than

    either method. The mass-averaged result falls between the two

    other methods. Based on this comparison, each method would

    appear to provide a consistent basis for comparison with

    predictions. The mass-averaged method has the advantage o

    using a measured quantity that has less variation hub to shroud

    than the other methods and is less sensitive to the flow ratio of

    the core flow to the sidestream flow. Finally, the mass

    averaging method also allows for a direct comparison between

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    one-dimensional predictions, CFD and test results, as the

    required information is typically readily available.

    CONCLUSIONS

    This paper presents results from a recent sidestream design

    study and compares the analytical results to test measurements.

    The new method builds on the prior works of Hardin (2002),

    Sorokes et al (2000) and Sorokes et al (2006). Based on this

    study, a modification to the published methodology has been

    proposed to improve the calculation of the inlet pressure for

    standard incoming sidestreams. Using the new method, it is

    possible to predict the sidestream exit pressure within an

    accuracy of 1.5%. This method enhancement will make it

    possible to provide more accurate sidestream pressure levels,

    thereby improving the process modeling for new or upgraded

    facilities.

    The comparison of test results with different averaging

    methods has shown that each method offers consistent, though

    somewhat different result. Based on this study, it is felt that

    mass averaging of the core flow pressure and the sidestream

    pressure provides the most effective reference for correlation of

    the impeller inlet total pressure.

    DISCLAIMER

    The information contained in this document consists of

    factual data, and technical interpretations and opinions which,

    while believed to be accurate, are offered solely for

    informational purposes. No representation or warranty is made

    concerning the accuracy of such data, interpretations and

    opinions.

    NOMENCLATURE

    V = VelocityR = Radius of Curvature

    N = Rotational Speed

    D = Impeller Outer Diameter

    Q = Volume Flow

    U = Tip Speed, DN

    n = Polytropic Exponent,

    2

    1

    1

    2

    ln

    P

    Pln

    = Density

    = Specific Volume

    = Inlet Flow Coefficient,3

    2 ND

    Q

    = Polytropic Head Coefficient,( )

    2

    1122

    U

    P-P1-n

    n

    PT = Total Pressure

    PS = Static Pressure

    TT = Total Temperature

    Ret = Return Channel Exit

    SS = Sidestream Exit

    Flg = Sidestream Flange

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    ACKNOWLEDGEMENTS

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    The authors thank Dresser-Rand Company for funding this

    overall project and for allowing the publication of this work.

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